Methods & systems for the automated operation and control of a continuous loop pump

Abstract

Systems and methods for automating the extraction of oil from an oil well, especially low production orphan wells. The system includes an endless loop pump extending into the oil well; a rotational drive motor operably connected to the loop pump; a transfer pump for conveying petroleum product away from the endless loop pump; a microprocessor controller for controlling the rotational drive motor and transfer pump; a number of sensors for sending operational measurements to the microprocessor indicative of the operational characteristics of the rotational drive motor; a collection reservoir for gathering the petroleum product from the endless loop pump; and a liquid level sensor for sending a level measurement to the microprocessor indicative of the level of the petroleum product in the collection reservoir. The system includes a variable sheave-pulley configuration and arrangement as well as complete local and remote system monitoring and reporting. The methods include automated production transfer (and reporting) to storage facilities (tank battery); automated starting and stopping of the loop pump in response to production variations; and improved safety processes for the containment, capture, and processing of casing head gases and liquid products.

1 . A system for automating the extraction of oil from an oil well, the system comprising:
 (a) an endless loop pump extending into the oil well;   (b) a rotational drive motor operably connected to the loop pump;   (c) a microprocessor controller for controlling the rotational drive motor; and   (d) at least one sensor for sending at least one operational measurement to the microprocessor controller indicative of the operational characteristics of the rotational drive motor.   
   
   
       2 . A system for automating the transfer of petroleum product from an endless loop pump, the system comprising:
 (a) a collection reservoir for gathering the petroleum product from the endless pump;   (b) a liquid level sensor for sending a level measurement indicative of a level of the petroleum product in the collection reservoir;   (c) a transfer pump for conveying the petroleum product away from the endless loop pump; and   (d) a microprocessor controller for controlling operation of the transfer pump.   
   
   
       3 . A system for automating the extraction of liquid petroleum from an oil well, the system comprising:
 (a) an endless loop pump extending into the oil well;   (b) a rotational drive motor operably connected to the loop pump;   (c) a collection reservoir for gathering the petroleum product from the endless loop pump;   (d) a liquid level sensor for sending a level measurement indicative of the level of the petroleum product in the collection reservoir;   (e) a transfer pump for conveying the petroleum product away from the endless loop pump;   (f) a microprocessor controller for controlling the rotational drive motor and the transfer pump; and   (g) at least one sensor for sending at least one operational measurement to the microprocessor controller indicative of the operational characteristics of the rotational drive motor.   
   
   
       4 . The system of  claim 3  wherein the microprocessor controller further comprises:
 (a) an endless loop pump control module for controlling operation of the endless loop pump;   (b) a liquid level control module for monitoring and recording a level of liquid petroleum product in the collection reservoir;   (c) a gas flow control module for monitoring and recording a volume of well head gases collected by the endless loop pump;   (d) an alarm module for monitoring and reporting alarm conditions in the operation of the system; and   (e) a communication module for data transfer and reporting to and from a remote location.   
   
   
       5 . The system of  claim 4  wherein the rotational drive motor further comprises a variable speed motor and the endless loop pump control module serves to control the variable speed. 
   
   
       6 . The system of  claim 4  wherein the at least one sensor comprises a torque sensor which communicates torque measurements to the endless loop pump control module for controlling the operation of the rotational drive motor. 
   
   
       7 . The system of  claim 4  wherein the liquid level control module receives input from the liquid level sensor and thereby serves to control the operation of the transfer pump for a predetermined time interval to convey the liquid petroleum product away from the collection reservoir. 
   
   
       8 . The system of  claim 3  further comprises a well head gas collection system whereby the well head gas is conducted away from the endless loop pump. 
   
   
       9 . The system of  claim 8  wherein the well head gas collection system further comprises a gas pressure sensor and a controllable valve and the microprocessor controller serves to operate the controllable valve upon input from the gas pressure sensor to conduct the well head gases away from the endless loop pump. 
   
   
       10 . The system of  claim 3  further comprising an intrusion detection system. 
   
   
       11 . The system of  claim 4  wherein the alarm module communicates alarm conditions in the operation of the system to a local alarm broadcast device. 
   
   
       12 . The system of  claim 4  wherein the communication module communicates data between the microprocessor controller and a remote system by wireless means. 
   
   
       13 . The system of  claim 3 , further comprising a pressurizable system enclosure, the system enclosure comprising:
 (a) a liquid product enclosure generally defining the collection reservoir for containing the liquid petroleum product collected by the endless loop pump; and   (b) a gas product enclosure for collecting the well head gas product collected during operation of the endless loop pump.   
   
   
       14 . The system of  claim 13  wherein the system enclosure further comprises a means for mounting the endless loop pump. 
   
   
       15 . The system of  claim 3  further comprising:
 (a) a hydrophobic material loop member extending into the oil well to a point below the surface of the liquid petroleum in the oil well; and   (b) a plurality of pulleys at the surface of the oil well whereby the hydrophobic material loop member traverses and is driven by the pulleys and the petroleum liquid is extracted from the hydrophobic loop into the collection reservoir by tension between the pulleys.   
   
   
       16 . A method for automated operation of a transfer pump operable in association with an oil well endless loop pump, the method comprising the steps of:
 (a) providing an automated controller connected to the transfer pump;   (b) monitoring a collection reservoir liquid level associated with the endless loop pump;   (c) initiating operation of the transfer pump when a liquid level in the collection reservoir exceeds a specified limit;   (d) measuring a volume of liquid product transferred from the collection reservoir; and   (e) communicating to a remote location a record of the transfer of product.   
   
   
       17 . A method for automated operation of an oil well endless loop pump and a transfer pump associated therewith, the method comprising the steps of:
 (a) providing an automated controller connected to a drive motor on the endless loop pump and to the transfer pump;   (b) monitoring a torque experienced by the drive motor;   (c) triggering an alarm when the torque exceeds pre-defined limits;   (d) monitoring a liquid level in a collection reservoir associated with the endless loop pump;   (e) initiating the operation of the transfer pump when the collection reservoir liquid level exceeds pre-defined limits;   (f) measuring a volume of liquid product transferred from the collection reservoir; and   (g) communicating to a remote location a record of the transfer of product.